Method for manufacturing swirler

Abstract

The invention belongs to the technical field of hydrocyclone equipment, and discloses a hydrocyclone manufacturing method which comprises the following steps: establishing a three-dimensional model of a hydrocyclone; performing data processing on the three-dimensional model of the cyclone; according to the three-dimensional model, subjected to data processing, of the cyclone, metal 3D printing of the cyclone is conducted; and subsequent treatment is conducted on the cyclone obtained after metal 3D printing is completed. The stability of the blade surface quality of the cyclone can be improved, meanwhile, the manufacturing process can be simplified, and the manufacturing period can be greatly shortened.

Description

Technical Field

[0001] The invention relates to the technical field of cyclone equipment, and in particular to a method for manufacturing a cyclone. Background Art

[0002] Swirls are widely used in aero engines, gas turbines, chemical equipment and other fields. For example, in aero engines, the swirler has a complex structure and contains blade structures inside. The blade structure is crucial to the optimization of the airflow. Therefore, when manufacturing the swirler, the surface roughness of the blades is generally required to be high.

[0003] Traditional aircraft engine cyclone manufacturing methods usually use precision casting to obtain blanks, which are then machined to obtain the final product. This manufacturing process is prone to metallurgical defects (such as pores), resulting in unstable blade surface quality, complex process flow and long manufacturing cycle.

[0004] Therefore, it is urgent to propose a manufacturing method of a cyclone to solve the above technical problems. Summary of the invention

[0005] The object of the present invention is to provide a method for manufacturing a swirler, which can improve the stability of the surface quality of the blades of the swirler and, at the same time, can simplify the manufacturing process and significantly shorten the manufacturing cycle.

[0006] As conceived above, the technical solution adopted by the present invention is:

[0007] The present invention provides a method for manufacturing a cyclone, comprising:

[0008] Establishing a three-dimensional model of the cyclone;

[0009] Performing data processing on the three-dimensional model of the cyclone;

[0010] Performing metal 3D printing of the cyclone according to the three-dimensional model of the cyclone after data processing;

[0011] The cyclone completed by metal 3D printing is subsequently processed.

[0012] In some embodiments, data processing is performed on the three-dimensional model of the cyclone, including:

[0013] Model positioning: the three-dimensional model of the cyclone is placed vertically on the virtual printing substrate, and the opening of the three-dimensional model of the cyclone faces upward.

[0014] In some embodiments, after the model is positioned, the method further includes:

[0015] adding a support structure to the three-dimensional model of the cyclone;

[0016] After the support structure is added, the three-dimensional model of the cyclone is sliced.

[0017] In some embodiments, the cyclone completed by metal 3D printing is subsequently processed, including:

[0018] Cleaning the remaining powder on the cyclone after metal 3D printing;

[0019] The cleaned cyclone is heat treated.

[0020] In some embodiments, the cleaned cyclone is subjected to heat treatment, specifically: the cyclone is sequentially subjected to a first heating stage, a first heat preservation stage, a second heating stage, and a second heat preservation stage;

[0021] The first heating stage is: heating from 30°C to 600°C-650°C in 90 minutes;

[0022] The first heat preservation stage is: heat preservation at 600°C-650°C for 30 minutes;

[0023] The second heating stage is: after the first heat preservation stage is completed, the temperature is raised to 1100°C-1200°C in 90 minutes;

[0024] The second heat preservation stage is: heat preservation at 1100° C.-1200° C. for 70 minutes.

[0025] In some embodiments, after the cleaned cyclone is heat treated, the following steps are performed:

[0026] Separating the cyclone from the printing platform by wire cutting;

[0027] The physical support structure on the cyclone is removed.

[0028] In some embodiments, after removing the physical support structure on the cyclone, the method further comprises:

[0029] The blades inside the cyclone are subjected to primary grinding and abrasive flow grinding in sequence.

[0030] In some embodiments, the material used in metal 3D printing is GH3536 powder, and the particle size of the GH3536 powder is 15 μm-53 μm.

[0031] In some embodiments, metal 3D printing uses laser as an energy source.

[0032] In some embodiments, during metal 3D printing, the laser scanning power is 280W-320W, the laser scanning speed is 900mm / s-1200mm / s, and the spacing between adjacent scanning paths is 0.1mm-0.13mm.

[0033] Beneficial effects of the present invention:

[0034] The manufacturing method of the cyclone provided by the present invention directly manufactures the finished cyclone product through metal 3D printing technology, omitting the traditional casting process step, avoiding metallurgical defects that are easy to occur in the casting process step, thereby improving the stability of the surface quality of the cyclone blades. At the same time, metal 3D printing can form complex structures in one piece, simplifying the manufacturing process and greatly shortening the manufacturing cycle. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments of the present invention. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the contents of the embodiments of the present invention and these drawings without paying any creative work.

[0036] Figure 1 is a flow chart of a method for manufacturing a cyclone provided in an embodiment of the present invention;

[0037] Figure 2 is a schematic diagram of the structure of a cyclone provided in an embodiment of the present invention;

[0038] Figure 3 It is a schematic diagram of the structure of the cyclone and the printing platform provided in an embodiment of the present invention.

[0039] In the figure:

[0040] 100. Cyclone;

[0041] 200. Printing platform. DETAILED DESCRIPTION

[0042] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0043] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0044] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0045] In the description of the present invention, it should be noted that the terms "upper", "lower", "left", "right", "vertical", "horizontal", "inside", "outside", etc. indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, or are the positions or positional relationships in which the inventive product is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", "third", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0046] In the description of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "disposed" and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0047] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0048] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be understood as limiting the present invention.

[0049] like Figure 1-Figure 3 As shown, the manufacturing method of the cyclone provided in this embodiment includes:

[0050] S1. Establishing a three-dimensional model of the cyclone 100;

[0051] S2, performing data processing on the three-dimensional model of the cyclone 100;

[0052] S3, performing metal 3D printing of the cyclone 100 according to the three-dimensional model of the cyclone 100 after data processing;

[0053] S4, performing subsequent processing on the cyclone 100 completed by metal 3D printing. After the subsequent processing is completed, the final product of the cyclone 100 is manufactured.

[0054] The manufacturing method of the cyclone provided in this embodiment directly manufactures the finished product of the cyclone 100 through metal 3D printing technology, omitting the traditional casting process step, avoiding metallurgical defects that are easy to occur in the casting process step, thereby improving the stability of the surface quality of the blades of the cyclone 100. At the same time, metal 3D printing can form complex structures in one piece, simplifying the manufacturing process and greatly shortening the manufacturing cycle.

[0055] In some embodiments, step S2, processing the three-dimensional model of the cyclone 100, includes:

[0056] Model positioning: the three-dimensional model of the cyclone 100 is placed vertically on the virtual printing substrate, and the opening of the three-dimensional model of the cyclone 100 faces upward.

[0057] It should be noted that: Figure 2 and Figure 3 As shown, Figure 3 is a schematic diagram of the physical structure of the cyclone 100 and the printing platform 200, Figure 3 The actual position relationship shown in is consistent with the virtual position relationship in the model positioning step. That is, the model is first positioned in the virtual space to determine the position, angle and direction of the three-dimensional model of the cyclone 100, and then the physical metal 3D printing is performed accordingly.

[0058] By placing the three-dimensional model of the cyclone 100 vertically with the opening facing upward, the 3D printer can deposit the material more evenly, avoid tilting or warping due to unstable models, and ensure that each layer of material can be stacked on the previous layer smoothly and accurately to maintain the flatness of the printed layer. The upward opening posture also helps the airflow to be discharged smoothly during the printing process, preventing material accumulation, thereby ensuring that the cyclone 100 can be accurately formed according to the design requirements.

[0059] Optionally, the printing substrate is made of stainless steel.

[0060] In some embodiments, after the model is positioned, the method further includes:

[0061] Adding a support structure to the three-dimensional model of the cyclone 100;

[0062] After the support structure is added, the three-dimensional model of the cyclone 100 is sliced.

[0063] The support structure here is a virtual structure added by the design software. The function of the support structure is to provide temporary support for the overhanging part of the model to prevent collapse or deformation due to gravity during the subsequent printing process. The physical support structure will be printed and generated together with other structures of the cyclone 100. After printing, the physical support structure will be removed from the cyclone 100 body to obtain the final product of the cyclone 100. The slicing process will divide the three-dimensional model into layers of two-dimensional slices and generate a command file that the 3D printer can understand, so that the 3D printer can build the object layer by layer according to the path of each layer.

[0064] In some embodiments, step S4, performing subsequent processing on the cyclone 100 completed by metal 3D printing, includes:

[0065] Cleaning the remaining powder on the cyclone 100 after metal 3D printing;

[0066] The cleaned cyclone 100 is subjected to heat treatment.

[0067] The heat treatment specifically includes: making the cyclone 100 enter a first heating stage, a first heat preservation stage, a second heating stage and a second heat preservation stage in sequence.

[0068] The first heating stage is: from 30℃ to 600℃-650℃ in 90 minutes;

[0069] The first heat preservation stage is: heat preservation at 600℃-650℃ for 30 minutes;

[0070] The second heating stage is: after the first heat preservation stage is completed, it takes 90 minutes to heat up to 1100℃-1200℃;

[0071] The second heat preservation stage is: heat preservation at 1100° C.-1200° C. for 70 minutes. After the second heat preservation stage is completed, the cyclone 100 is immediately taken out of the heat treatment furnace and air-cooled.

[0072] In metal 3D printing technology, the printing material is usually metal powder, which is locally heated, melted and deposited layer by layer. Therefore, during the printing process, the printing material will experience rapid heating and cooling, which will produce residual stress. Through the precisely controlled heating and insulation stages, these residual stresses can be effectively eliminated, avoiding structural deformation or rupture of the cyclone 100 due to stress concentration during subsequent use, and improving the overall structural stability and durability.

[0073] In some embodiments, after the cleaned cyclone 100 is subjected to heat treatment, the following steps are performed:

[0074] Separating the cyclone 100 from the printing platform 200 by wire cutting;

[0075] The physical support structure on the cyclone 100 is removed.

[0076] Wire cutting technology can provide a high degree of precision and control, and wire cutting and removal of the solid support structure can quickly and efficiently complete the separation and finishing of the finished product of the cyclone 100.

[0077] Furthermore, after removing the physical support structure on the cyclone 100, the method further includes:

[0078] The blades inside the cyclone 100 are subjected to primary grinding and abrasive flow grinding in sequence.

[0079] Initial grinding generally uses tools such as sandpaper or grinding wheels to perform rough machining on the blade surface and remove surface defects on a large scale. Abrasive flow grinding is fine machining. Its basic principle is to push a fluid containing abrasive particles (usually oil or water-based fluid) under a specific pressure through the surface of the workpiece for friction and cutting to achieve the purpose of improving surface finish and shape accuracy. The abrasive flow can penetrate into complex and narrow internal areas for fine grinding. In this way, the surface smoothness of the blade can be effectively improved, thereby effectively reducing the resistance of the airflow passing through, optimizing the fluid dynamics performance of the cyclone 100, and improving its working efficiency.

[0080] In some embodiments, the material used in metal 3D printing is GH3536 powder, and the particle size of the GH3536 powder is 15 μm-53 μm.

[0081] GH3536 is a solid solution strengthened high temperature alloy. The metal parts formed by 3D printing from its powder have excellent high temperature strength and oxidation resistance. Furthermore, powder with moderate particle size helps to improve the performance stability of the final product at high temperature.

[0082] The composition of GH3536 powder is shown in the following table:

[0083]

[0084] The wt% in the table stands for weight percent, which refers to the percentage of the mass of a certain element in the alloy to the total mass. For example, the mass percentage of Cr in GH3536 ranges from 20.5% to 23%, which means that in 100 grams of alloy, the chromium content is approximately between 20.5 grams and 23 grams.

[0085] The "Bal." in the table stands for "Balance", which means the remainder. This means that in the composition of GH3536 alloy, nickel (Ni) is the main element, and its content accounts for the rest of the alloy. Specifically, other elements (such as chromium, iron, molybdenum, etc.) have clear mass percentage ranges, while the nickel content occupies all the remaining space in the alloy as a base metal, so it will not be expressed in specific numbers.

[0086] Optionally, metal 3D printing uses laser as the energy source. Laser has extremely high energy density and can quickly heat and melt metal powder. This high energy density allows the material to melt in a short time, ensuring faster printing speed and higher production efficiency.

[0087] Of course, in addition to laser metal 3D printing, in other embodiments, high-temperature gas generated by electron beam or plasma arc can also be used as an energy source, which is not specifically limited here.

[0088] In some embodiments, during metal 3D printing, the laser scanning power is 280W-320W. By way of example, the laser scanning power can be 280W, 290W, 300W, 310W or 320W, etc., which can be set according to actual needs; the laser scanning speed is 900mm / s-1200mm / s. By way of example, the laser scanning speed can be 900mm / s, 1000mm / s, 1100mm / s or 1200mm / s, etc., which can be set according to actual needs; the spacing between adjacent scanning paths is 0.1mm-0.13mm. By way of example, the spacing between adjacent scanning paths can be 0.1mm, 0.11mm, 0.12mm or 0.13mm, etc., which can be set according to actual needs.

[0089] Moderate laser scanning power can ensure effective melting while avoiding overheating and burning of materials, thereby achieving efficient material utilization and short printing time. The relatively small spacing between adjacent scanning paths helps to ensure good bonding between molten metal powders, reduce gaps and defects, and thus improve the density and mechanical properties of the finished product. Faster laser scanning speeds can reduce oxidation or roughness caused by overheating of the material during the printing process, and improve the surface quality of the finished product.

[0090] After later testing, the cyclone 100 manufactured by the manufacturing method of the cyclone provided in this embodiment has a dimensional error of 0.05mm-0.1mm; after metallographic porosity testing, the porosity is less than 0.03%, and the average defect size is 12μm; after mechanical property testing, the tensile strength after heat treatment is 710MPa±50MPa, the yield strength is 330MPa±50MPa, and the elongation is 45%±6%. The molding quality and dimensional tolerance are better than those of traditional casting.

[0091] Note that the above are only preferred embodiments of the present invention and the technical principles used. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and that various obvious changes, readjustments and substitutions can be made by those skilled in the art without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in more detail through the above embodiments, the present invention is not limited to the above embodiments, and may include more other equivalent embodiments without departing from the concept of the present invention, and the scope of the present invention is determined by the scope of the appended claims.

Claims

1. A method for manufacturing a cyclone, characterized in that: include: Establishing a three-dimensional model of the cyclone; Performing data processing on the three-dimensional model of the cyclone; Performing metal 3D printing of the cyclone according to the three-dimensional model of the cyclone after data processing; The cyclone completed by metal 3D printing is subsequently processed.

2. The method for manufacturing a cyclone according to claim 1, characterized in that: The three-dimensional model of the cyclone is subjected to data processing, including: Model positioning: the three-dimensional model of the cyclone is placed vertically on the virtual printing substrate, and the opening of the three-dimensional model of the cyclone faces upward.

3. The method for manufacturing a cyclone according to claim 2, characterized in that: After model positioning, it also includes: adding a support structure to the three-dimensional model of the cyclone; After the support structure is added, the three-dimensional model of the cyclone is sliced.

4. The method for manufacturing a cyclone according to claim 3, characterized in that: The cyclone completed by metal 3D printing is subsequently processed, including: Cleaning the remaining powder on the cyclone after metal 3D printing; The cleaned cyclone is heat treated.

5. The method for manufacturing a cyclone according to claim 4, characterized in that: The cleaned cyclone is heat treated, specifically: the cyclone is sequentially put into a first heating stage, a first heat preservation stage, a second heating stage and a second heat preservation stage; The first heating stage is: heating from 30°C to 600°C-650°C in 90 minutes; The first heat preservation stage is: heat preservation at 600°C-650°C for 30 minutes; The second heating stage is: after the first heat preservation stage is completed, the temperature is raised to 1100°C-1200°C in 90 minutes; The second heat preservation stage is: heat preservation at 1100° C.-1200° C. for 70 minutes.

6. The method for manufacturing a cyclone according to claim 4, characterized in that: After the cleaned cyclone is heat treated, the method comprises: Separating the cyclone from the printing platform by wire cutting; The physical support structure on the cyclone is removed.

7. The method for manufacturing a cyclone according to claim 6, characterized in that: After removing the solid support structure on the cyclone, the method further comprises: The blades inside the cyclone are subjected to primary grinding and abrasive flow grinding in sequence.

8. The method for manufacturing a cyclone according to any one of claims 1 to 7, characterized in that: The material used in metal 3D printing is GH3536 powder, and the particle size of the GH3536 powder is 15μm-53μm.

9. The method for manufacturing a cyclone according to claim 1, characterized in that: Metal 3D printing uses laser as the energy source.

10. The method for manufacturing a cyclone according to claim 9, characterized in that: During metal 3D printing, the laser scanning power is 280W-320W, the laser scanning speed is 900mm / s-1200mm / s, and the spacing between adjacent scanning paths is 0.1mm-0.13mm.

Images